Skip to main content
SpringerLink
Log in

Optimization of High Porosity Thermal Barrier Coatings Generated with a Porosity Former

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

Yttria-stabilized zirconia thermal barrier coatings are extensively used in turbine industry; however, increasing performance requirements have begun to make conventional air plasma sprayed coatings insufficient for future needs. Since the thermal conductivity of bulk material cannot be lowered easily; the design of highly porous coatings may be the most efficient way to achieve coatings with low thermal conductivity. Thus the approach of fabrication of coatings with a high porosity level based on plasma spraying of ceramic particles of dysprosia-stabilized zirconia mixed with polymer particles, has been tested. Both polymer and ceramic particles melt in plasma and after impact onto a substrate they form a coating. When the coating is subjected to heat treatment, polymer burns out and a complex structure of pores and cracks is formed. In order to obtain desired porosity level and microstructural features in coatings; a design of experiments, based on changes in spray distance, powder feeding rate, and plasma-forming atmosphere, was performed. Acquired coatings were evaluated for thermal conductivity and thermo-cyclic fatigue, and their morphology was assessed using scanning electron microscopy. It was shown that porosity level can be controlled by appropriate changes in spraying parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

References

  1. R. Miller, Thermal Barrier Coatings for Aircraft Engines: History and Directions, J. Therm. Spray Technol., 1997, 6(1), p 4-35

    Article  Google Scholar 

  2. D. Stöverand and C. Funke, DIRECTIONS of the development of Thermal Barrier Coatings in Energy Applications, J. Mater. Process. Technol., 1999, 92-93, p 195-202

    Article  Google Scholar 

  3. R. Harnacha, P. Fauchais, and F. Nardou, Influence of Dopant on the Thermal Properties of Two Plasma-Sprayed Zirconia Coatings Part I: Relationship Between Powder Characteristics and Coating Properties, J. Therm. Spray Technol., 1996, 5(4), p 431-438

    Article  Google Scholar 

  4. N. Markocsan, P. Nylen, and J. Wigren, Low thermal Conductivity Coatings for Gas Turbine Applications, J. Therm. Spray Technol., 2007, 16(4), p 498-505

    Article  Google Scholar 

  5. N. Curry, N. Markocsan, X.-H. Li, A. Tricoire, and M. Dorfman, Next Generation Thermal Barrier Coatings for the Gas Turbine Industry, J. Therm. Spray Technol., 2010, 20(1-2), p 108-115

    Article  Google Scholar 

  6. N. Curry, N. Markocsan, L. Östergren, X.-H. Li, and M. Dorfman, Evaluation of the Lifetime and Thermal Conductivity of Dysprosia-Stabilized Thermal Barrier Coating Systems, J. Therm. Spray Technol., 2013, 22(6), p 672-864

    Article  Google Scholar 

  7. F. Cernuschi, L. Lorenzoni, S. Ahmaniemi, P. Vuoristo, and T. Mäntylä, Studies of the Sintering Kinetics of Thick Thermal Barrier Coatings by Thermal Diffusivity Measurements, J. Eur. Ceram. Soc., 2005, 25(4), p 393-400

    Article  Google Scholar 

  8. L. Xie, M.R. Dorfman, A. Cipitria, S. Paul, I.O. Golosnoy, and T.W. Clyne, Properties and Performance of High-Purity Thermal Barrier Coatings, J. Therm. Spray Technol., 2007, 16(5), p 804-808

    Article  Google Scholar 

  9. N. Curry and J. Donoghue, Evolution of Thermal Conductivity of Dysprosia Stabilised Thermal Barrier Coating Systems During Heat Treatment, Surf. Coat. Technol., 2012, 209, p 38-43

    Article  Google Scholar 

  10. R.E. Taylor, Thermal Conductivity Determinations of Thermal Barrier Coatings, Mater. Sci. Eng. A, 1998, 245(2), p 160-167

    Article  Google Scholar 

  11. J. Wigren, “High Insulation Thermal Barrier Systems—HITS”, BriteEuram Project BE96-3226, 2002

  12. N. Curry, W. Janikowski, Z. Pala, M. Vilemova, and N. Markocsan, Impact of Impurity Content on the Sintering Resistance and Phase Stability of Dysprosia- and Yttria-Stabilized Zirconia Thermal Barrier Coatings, J. Therm. Spray Technol., 2014, 23(1-2), p 160-169

    Article  Google Scholar 

Download references

Acknowledgments

This work was partially supported by the Czech Science Foundation under Grant No. 14-36566G Multidisciplinary research centre for advanced materials. The authors are grateful for extensive technical support and help with spaying to Stefan Björklund, Production Technology Centre.

Author information

Authors and Affiliations

  1. Czech Technical University in Prague, Prague, Czech Republic

    Jan Medřický

  2. Institute of Plasma Physics AS CR, Prague, Czech Republic

    Zdenek Pala, Monika Vilemova & Tomas Chraska

  3. University West, Trollhättan, Sweden

    Nicholas Curry & Nicolaie Markocsan

  4. GKN Aerospace Engine Systems, Trollhättan, Darrasa, Sweden

    Jimmy Johansson

Authors
  1. Jan Medřický
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Nicholas Curry
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zdenek Pala
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Monika Vilemova
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Tomas Chraska
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jimmy Johansson
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Nicolaie Markocsan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jan Medřický.

Additional information

This article is an invited paper selected from presentations at the 2014 International Thermal Spray Conference, held May 21-23, 2014, in Barcelona, Spain, and has been expanded from the original presentation.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Medřický, J., Curry, N., Pala, Z. et al. Optimization of High Porosity Thermal Barrier Coatings Generated with a Porosity Former. J Therm Spray Tech 24, 622–628 (2015). https://doi.org/10.1007/s11666-014-0214-y

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-014-0214-y

Keywords

Search

Navigation